IMTS Pavilion: EDM
As far as Fletcher knows, “there isn’t another EDM maker in the world that offers automatic wire changing capability.” He explains that traditionally, “wire EDM was a single-tool pro- cess”—one would have to stop to change wires if one wanted a different diameter of wire. With automatic wire changing, “We remove that manual intervention, so that customers can, for example, rough with one diameter of wire and then finish with a second diameter, but do it all automatically.” Just as one would no longer expect to buy a machining center without the option of an automatic toolchanger, Fletcher thinks auto- matic wire changing capability will become the norm in EDM.
“Input costs are always a consideration when running an EDM machine –or several EDM machines—and many custom- ers are looking to reduce cost of operation,” Langenhorst said. “Ultimately, the goal is to reduce the cost per component to ei- ther deliver a more competitively priced part or improve margin on product. This is where we have seen some major successes with our MV series of wire EDM.” The series features a novel cylindrical drive system that features a round magnetic shaft replacing the ballscrew, creating a 360° magnetic flux for a no- contact, and thus low-maintenance, motor design. “Customers have responded extremely well to the ma-
chine’s low cost of operation—wire consumption, power con- sumption, and maintenance costs are all remarkably low, and that seems to be a real trigger,” Langenhorst said. “The repeat purchases after that first MV series purchase have really told us how valuable operational cost savings are to those in the EDM market right now.”
GF Machining Solutions Cut 2000 machine features a novel automatic wire changing capability.
The second trend Fletcher is seeing is an increased demand for custom solutions: fewer customers are willing to buy a one-size-fits-all machine and then try to adapt their processes to it, he said. “We’re certainly seeing this in the aerospace industry,” he noted, pointing to two machines that will be at IMTS as examples of the trend. “The Drill 300 was designed specifically for cooling holes in airfoils and came about directly as a consequence of requests from major jet- engine manufacturers,” he said. “And we developed the Cut 200 Aerotech in conjunction with Pratt & Whitney, specifically for the machining of the fir-tree form in the turbine disk. “Finding these kinds of dedicated solutions is something that we like doing and expect to be doing more of,” he concluded.
Large Parts, Lower Costs
Cost of operation is on the mind of EDM customers of MC Machinery Systems Inc. (Wood Dale, IL), according to Techni- cal Marketing Manager Greg Langenhorst.
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MC Machinery Systems’ MV4800 Advance features a Y travel of 800 × 600 × 500 mm.
Langenhorst said that they are also seeing a greater demand for machines that can handle large parts. “Previous machines from MC Machinery, including the FA30V Advance, have done a fine job as far as tall parts go, but they didn’t quite hit the mark on large round parts. That’s where the new MV 4800 has stepped up to the plate, taking care of larger round parts with the additional Y travel. The MV4800 Advance features a travel of 800 × 600 × 500 mm and can machine workpieces up to 1.3 × 1.1 × 0.5 m. Submerged, it cuts as much as 500-mm deep.”
The Fine Art of Surfacing At Methods Machine Tools Inc. (Sudbury MA), customers have a growing concern for the small, according to Stephen
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